Customized Steam Cycle Water Chemistry Guidelines

for Fossil Fuel Utility, Industrial, and Combined Cycle Units

Background

These comprehensive Guidelines, customized for a specific unit, cover water and steam chemistry control for utilities, industrial units, and combined cycles for any type of water treatment. These Guidelines also discuss the basics of water chemistry and corrosion control, management aspects, and cycle design, provide rationale and a description of cycle chemistry control, give operating limits for condensate, feedwater, boiler water, steam, makeup, and return condensate, and specify action levels, monitoring, sampling, and instrumentation.

The Guidelines relate the cycle and component design to selection of water treatment and cover normal operation, startups, and layup. Chemical cleaning, quality control of water treatment chemicals and ion exchange resins, control of chemical contamination by extraneous substances and problem recognition, operator actions, and engineering solutions to problems are also discussed.

Sample Table of Contents

1 Introduction

1.1 SYstem Consideration

1.2 Boiler or HRSG Concerns

1.3 Steam Turbine Consideration

1.4 Condenser Considerations

1.5 Environmental Considerations

2 Management

3 Cycle Description

4 Selection of the water treatment, sample points, action levels, and target values

4.1 Introduction

4.2 Selection of Water Treatment

4.3 Rational for Sample Point

4.4 Rational for Action LEvels

4.5 Rationale for Target Values

4.6 CHemical Addition Points

5 Control Limits

6 Water and Steam for Gas Turbine Injection (Where applicable)

6.1 Target Values

6.2 Overall Limits

6.3 Compatibility of the Water/Steam and the Gas Turbine Materials

7 Guidelines for Startuo, Cycling and Peaking Operations, and Commissioning

7.1 Start Up

7.2 Cycling and PEaking Operations

7.3 Commissioning

8 Corrective Actions

8.1 Short-Term Corrective Actions

8.2 Long-Term Corrective Actions

8.3 Sale and Deposit Builduo

8.4 Corrosion Damage

9 Layup Practices

10 Chemical Cleaning

10.1 Chemical Cleaning of Boilers / HRSG

10.2 Cleaning of Turbines, COndensers, and Evaporators

11 Reference and Bibliography

Appendix A - Representative Sampling

A.1 Factors Affecting Sampling

A.2 Sampling Systems

A.3 Grab Sample Procedures

A.4 Sampling System Maintenance

A.5 Turbine Deport Collector / Simulator

Appendix B - Water and Steam Chemistry Monitoring

B.1 Proper Method Selection

B.2 Calibration Techniques

B.3 Operation and Maintenenace

Appendix C - QA/QC for Sampling and Analysis

C.1 Definitions

C.2 QA/QC for Sampling

C.3 QA/QC for On-Line Instruments

C.4 Charting of Instruments Performance

C.5 Summary

C.6 QA/QC for Laboratory Procedures

Appendix D - Data Collection, Interpretation, and Management

D.1 Data Collection

D.2 Data Storage and Retrieval

D.3 Data Analysis and Interpertation

D.4 Expert Systems

Appendix E - Other Considerations

E.1 Quality Control of Water Treatment Chemicals, Ion Exchange Resins, and Activated Carbon

E.2 Ion Exchange Systems Performance Testing

E.3 Control of Chemical Contamination by Extraneous Substances

E.4 Monition of Corrosion and Scale / Deposits

E.5 Oxide Exfoliation and Solid Particle Erosion

Appendix F - Common Terms and Definitions

Appendix G - Useful Graphs and Tables